Three-Stage Multiphase Sand Separator for Hydrocarbon Recovery

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Solution Overview

Problem

Existing sand separation systems face challenges such as inefficiency in removing particulate matter from multiphase streams, particularly in hydrocarbon production from fractured wells, leading to issues like liquid slugs overwhelming single-stage devices and loss of valuable hydrocarbons.

Innovation Solution

A three-stage system comprising a first vessel for gas separation, a second vessel for liquid and particulate matter separation with a pressure head generation, and a third vessel for collecting and conveying the particulate matter, allowing for efficient removal and recovery of hydrocarbons.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single-stage sand separation device is used, then the device complexity is reduced, but the productivity and reliability of particulate matter removal deteriorates due to liquid slugs overwhelming the device

Engineering Contradiction:
Improvedevice complexityVSAvoidparticulate matter removal efficiency
Core Design Contradiction:
Device complexityVSProductivity

Solution Approach 1:

The sand separation system is divided into multiple stages: a first sand separator for initial separation, a second sand separator for further separation, and a third sand separator for final separation. This segmentation allows each stage to handle specific portions of the multiphase stream, preventing liquid slugs from overwhelming a single device while maintaining manageable complexity at each stage.

Inventive Principle:
Principle #1Segmentation

2Device complexity

If a single-stage sand separation device is used, then the device complexity is reduced, but the reliability of sand separation deteriorates when faced with liquid slugs

Engineering Contradiction:
Improvedevice complexityVSAvoidsand separation reliability
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The system uses multiple sand separators arranged in series, where the first separator handles initial separation, the second separator processes intermediate material, and the third separator completes the separation. This segmented approach ensures that liquid slugs are progressively managed across stages, maintaining reliable sand separation without requiring an overly complex single-stage device.

Inventive Principle:
Principle #1Segmentation

3Productivity

If a multi-stage sand separation system is implemented, then the productivity and reliability of particulate matter removal is improved, but the device complexity increases

Engineering Contradiction:
Improveparticulate matter removal efficiencyVSAvoiddevice complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The multi-stage system is segmented into distinct functional units (first, second, and third sand separators), each performing a specific separation function. This segmentation improves productivity and reliability by distributing the separation load across multiple specialized stages, while the modular nature of the segmentation keeps each individual stage relatively simple.

Inventive Principle:
Principle #1Segmentation

4Reliability

If a multi-stage sand separation system is implemented, then the reliability of sand separation is improved, but the device complexity increases

Engineering Contradiction:
Improvesand separation reliabilityVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system segments the sand separation process into multiple reliable stages, where each sand separator is designed for its specific function. This segmentation enhances overall reliability by ensuring that each stage contributes to the separation process, while the modular segmented structure avoids the need for an overly complex single-stage design.

Inventive Principle:
Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively separates sand from hydrocarbons, reduces the risk of overfilling due to liquid slugs, and minimizes the loss of valuable hydrocarbons, achieving efficient and cost-effective sand removal and hydrocarbon recovery.

Implementation Method 1

a first vessel for receiving the multiphase stream and separating a majority of gas from the multiphase stream and collecting a slurry of liquid and particulate matter

Methodology Applied
Scientific EffectGravity separation: Gravitation

Implementation Method 2

a second vessel for receiving the slurry and causing separation of the particulate matter from the liquid and for generating a pressure head of liquid against the particulate matter

Methodology Applied
Scientific EffectPressure head generation: Pressure Gradient

Implementation Method 3

a pressure head element, also referred to herein as a conditioner, connected to the second vessel via a liquid conduit, the pressure head element having an inner diameter greater than the liquid conduit's inner diameter

Methodology Applied
Scientific EffectPressure head enhancement: Pressure Gradient

Data Source

PatentUS12290764B2Method and apparatus for removal of particulate matter from a multiphase stream
Publication Date: 2025.05.06 2144811 ALBERTA INC
  • US12290764B2 patent drawing
  • US12290764B2 patent drawing
  • US12290764B2 patent drawing

AI summary

A system for removing particulate matter from a multiphase stream comprising gas, liquid and the particulate matter. The system comprises a first vessel for receiving the multiphase stream and separating a majority of gas from the multiphase stream and collecting a slurry of liquid and particulate matter; a second vessel for receiving the slurry and causing separation of the particulate matter from the liquid and for generating a pressure head of liquid against the particulate matter; a third vessel for receiving the particulate matter from the second vessel and collecting the particulate matter until a pre-determined mass or volume of particulate matter is collected; and an outlet in the third vessel for conveying the particulate matter out of the third vessel.